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BLIIOT BL190 Modbus TCP Edge I/O Controller

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IIoT EdgeIO Controller BL192Pro

Name: IIoT EdgeIO Controller BL192Pro
Brand: Beilai Tech. Co., Ltd.
SKU: BL192Pro
Availability: InStock
Rating: 5 (1 reviews)

No.BL192Pro

IIoT EdgeIO controller supporting MQTT, OPC UA, and Modbus TCP in one device. Collect Modbus RTU/TCP or local I/O data. Publish simultaneously to cloud (MQTT), enterprise systems (OPC UA), and PLCs/SCADA (Modbus TCP). Expandable with 1-3 Y Series I/O boards. -40°C to +85°C.

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Description
Model Selection

⚡ Multi‑Protocol Edge I/O Controller for IIoT & Smart Manufacturing

BL192Pro EdgeIO Controller

One device replaces "PLC + I/O modules + protocol gateway + cloud gateway". Natively supports MQTT, Modbus TCP, OPC UA, and Modbus RTU – for seamless data flow from field devices to cloud and IT systems.

✔ MQTT · Modbus TCP · OPC UA · Modbus RTU ✔ -40°C ~ +85°C wide temperature ✔ 1–3 I/O expansion slots (Y‑series)

Product Overview

Unified Edge Controller for IIoT, Cloud, and IT Systems

The BL192Pro is a multi‑protocol EdgeIO controller from BLIIOT, purpose‑built for industrial IoT and smart manufacturing. Building on the native MQTT capabilities of BL192, it integrates Modbus TCP and OPC UA, enabling seamless data flow between field devices, local HMI/SCADA, cloud platforms, and IT systems.

One BL192Pro:

Acquires field sensors and instruments, executes local logic control
Acts as a Modbus RTU slave to connect with existing HMIs and touch panels – retain legacy operation
Uploads data to public/private clouds via MQTT for remote monitoring
Exposes data to MES, ERP, SCADA via OPC UA

Electrical isolation, EMC/EMI tested, -45°C~80°C validated, hardware watchdog, and support for Modbus RTU/TCP, MQTT, OPC UA – a highly reliable, easy‑to‑deploy, scalable edge solution for IIoT.

🏭

Model: BL192Pro

Multi‑Protocol EdgeIO Controller

✔ MQTT · Modbus TCP · OPC UA

✔ 1–3 expansion slots

✔ Modbus RTU master + slave

Why BL192Pro – Multi‑Protocol Fusion?

Industrial sites often face mixed protocols: legacy devices with hardwired signals, HMIs speaking Modbus RTU, cloud mandates MQTT, and IT wants OPC UA. Traditional approaches stack multiple gateways – high cost, many failure points, complex debugging.

Traditional Pain Points	BL192Pro Solution
Separate PLC for signal acquisition + protocol gateway for conversion	Single device does I/O acquisition + multi‑protocol conversion
Existing HMI cannot directly read data – requires reprogramming	BL192Pro acts as Modbus RTU slave – HMI works without changes
Cloud upload requires external 4G DTU or gateway	Native MQTT – straight to Alibaba Cloud, AWS IoT, ThingsBoard, etc.
IT systems cannot directly access OT data	OPC UA provides standardized, secure interface for upper‑level applications
High on‑site maintenance due to distributed devices	BLRAT remote tool – remote upgrade, debugging, troubleshooting

🔄 Acquired I/O data and Modbus slave data can be simultaneously mapped to Modbus registers, MQTT messages, and OPC UA nodes – one source, every destination.

Key Features

📡 Modbus RTU/TCPModbus RTU master (up to 25 commands) for instruments; Modbus RTU slave for HMI. Modbus TCP master/slave.
📟 MQTT ClientSupports Alibaba Cloud, AWS IoT, ThingsBoard, private brokers. QoS 0/1/2, TLS, offline buffering & data packing.
🔧 OPC UA ServerStandard OPC UA, multiple client connections. Anonymous/user authentication, X.509, AES‑256 encryption.
🔌 Flexible I/O Expansion1–3 slots, 20+ Y‑series modules: DI, DO, AI, AO, RTD, TC, high‑speed pulse (150kHz), etc.

🔗 Dual Ethernet Daisy Chain2× 10/100M Ethernet with switch function, simplifies cabling
🌐 Built‑in Web ConfigurationBrowser‑based logic (arithmetic, conditions, interlocking) – no proprietary software
📡 Remote O&M (BLRAT)Remote firmware upgrade, parameter tuning, diagnostics – no site visit
🎛️ Local Logic ControlIndependent arithmetic, conditional actions, interlocking – offloads main PLC

Technical Specifications – Base Controller

Power Supply

24V DC, 55mA@24VDC, reverse polarity protection

Ethernet

2× RJ45, 10/100M, isolated: ESD ±6kV/±8kV, EFT 1kV

RS485

1x isolated, baud rate 2400~230400 bps (Modbus RTU master/slave)

OS & Resources

Linux, 300MHz CPU, 64MB RAM, 128MB Flash

Uplink Protocols

MQTT Client (QoS 0/1/2, TLS, Alibaba Cloud/AWS/ThingsBoard/private)
Modbus TCP Server/Client (up to 15 TCP connections)
OPC UA Server (custom namespace, security: None/Basic128Rsa15/Basic256/Basic256Sha256)
Modbus RTU master (up to 25 commands) + slave (for HMI)

Operating Environment

-40°C ~ +85°C, 5%~95% RH

Mounting / Protection

Wall mount / DIN35 rail, IP30

Dimensions (1-slot/3-slot)

30×83×110 mm / 40×83×110 mm

Use Case: Legacy Production Line Smart Retrofit

Background: An auto parts factory had a stamping line built 10 years ago. The original PLC (discontinued) was failing. A local HMI communicated with the PLC via Modbus RTU for status display and manual control. The factory wanted to:

Keep the existing HMI interface – no retraining
Collect energy consumption and stamping counts (OEE) and upload to factory cloud platform
Enable remote diagnostics and parameter tuning to reduce downtime

✅ Retrofit with BL192Pro

I/O acquisition: DI captures press run/fault signals; AI captures current/pressure; high‑speed counter captures stamping count.
Local logic: Web‑configured logic – emergency stop → DO cut power; daily stamping count auto‑reset.
Modbus RTU slave: BL192Pro emulates the original PLC’s Modbus address map – HMI reads DI status and writes DO commands without any modification.
MQTT to cloud: Stamping count, peak current, runtime uploaded to private cloud – real‑time OEE dashboard.
OPC UA to MES: Key data exposed via OPC UA for quality traceability and analytics.
Remote O&M: Engineers use BLRAT to modify reset times, alarm thresholds, and diagnose faults – no site visits.

📉 Before Retrofit

▪ Hardware: obsolete PLC + discrete I/O
▪ HMI migration: would require full reprogramming
▪ Cloud upload: not supported
▪ MES integration: no interface
▪ On‑site maintenance: ≥1 visit/week
▪ Annual downtime: ~40 hours

📈 After Retrofit

▪ Single BL192Pro
▪ HMI unchanged – zero modification
▪ MQTT directly to cloud, real‑time monitoring
▪ OPC UA standard interface, plug‑and‑play
▪ Remote diagnostics – 80% fewer site visits
▪ Annual downtime reduced to <10 hours

Conclusion: BL192Pro modernizes legacy equipment with zero HMI changes, delivers cloud connectivity, and enables remote maintenance – dramatically reducing downtime and operational cost.

More IIoT & Smart Manufacturing Applications

🔧 OEM Equipment Integration
Pre‑equip BL192Pro into machinery for remote O&M – Modbus slave to existing HMI; MQTT allows OEM to monitor machine health remotely.

💧 Distributed Pump/Air Compressor Stations
Local control + data collection. Modbus slave for on‑site HMI; MQTT aggregates data to central platform; OPC UA to energy management system.

📊 Production Line OEE Monitoring
Collect equipment status, counts, alarms. Modbus slave to existing SCADA; MQTT to cloud dashboard; OPC UA to MES for analytics.

🕰️ Legacy Equipment Networking
Replace simple PLC with relay signals. Retain existing HMI (Modbus slave) while sending data to cloud – low‑cost equipment IoT enablement.

🔬 Laboratory Environment Monitoring
Temperature, humidity, equipment status. MQTT pushes alarms to mobile; OPC UA connects to LIMS.

Environment & Certifications

🌡️ Wide operating temperature
-40°C ~ +85°C

🛡️ Protection rating
IP30

📜 EMC compliance
CE/FCC certified, IEC61000-4-2/4/5 Level 3 (ESD, EFT, Surge)

📳 Vibration & drop
IEC60068-2-6 (sinusoidal vibration), IEC60068-2-31 (free fall)

✅ Hardware watchdog & full electrical isolation
✅ -45°C~80°C validation, anti‑interference design

✅ Dual Ethernet switch + isolated RS485
✅ Built‑in web configuration & remote O&M (BLRAT)

Support & Customization

✔ Custom R&D and manufacturing (OEM/ODM)
✔ Long‑term after‑sales support

Available I/O Modules

💡 Click behavior: Each click adds that module to the next available slot.
🔁 Duplicate allowed: Click same module 2 or 3 times to fill multiple slots (e.g. Y31 + Y31).
⚠️ Y61 (Serial) can be selected only once per controller.

Your Selection (Slots 1–3)

Total modules: 0 / 3

Configuration summary

No modules selected. Click any Y‑series module to occupy Slot 1 → Slot 2 → Slot 3.

✅ Fully compatible with BL192Pro, BL192, BL191, BL190, BL193, BA190, BA190Pro.
📌 Each slot = physical I/O board position. Identical models allowed (click again).

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